Backflow collection system and method for reclaiming the same

ABSTRACT

The present disclosure provides a collection receptacle and a method for reclaiming backflow from a wellbore. The collection receptacle, in one embodiment, includes an enclosure configured to collect solid and liquid matter, and an elevated auger extending into the enclosure and configured to remove the solid matter from the enclosure. In this embodiment, the auger includes a housing having an outside radius r h , a flighting having a radius r f , and a shaft of the flighting having a radius of r s , wherein a ratio (r s / f ) ranges from about 0.5 to about 0.6, and further wherein a relationship between the flighting radius r f  and shaft radius r s  promotes separation of the solid matter from the liquid matter as the solid matter travels up the auger and out of the enclosure.

CROSS-REFERENCE TO RELATED APPLICATION

This Application is a continuation application of U.S. patentapplication Ser. No. 13/735,879 filed on Jan. 7, 2013, entitled“BACKFLOW COLLECTION RECEPTACLE AND METHOD FOR RECLAIMING THE SAME” byBruce Thompson which is a continuation-in-Part of U.S. application Ser.No. 12/685,549, filed on Jan. 11, 2010, now issued as U.S. Pat. No.8,449,779 on May 28, 2013, entitled “BACKFLOW COLLECTION RECEPTACLE ANDMETHOD FOR RECLAIMING THE SAME” to Bruce Thompson, which claims thebenefit of Provisional Application Ser. No. 61/143,693 entitled “GasBuster/Sand Auger” by Bruce Thompson, filed on Jan. 9, 2009. U.S.application Ser. No. 12/685,549 also claims benefit of ProvisionalApplication Ser. No. 61/583,499 entitled “Oil Super Loop” by BruceThompson, filed on Jan. 5, 2012, all of which are commonly assigned withthe present disclosure and incorporated herein by reference as ifreproduced herein in its entirety.

TECHNICAL FIELD

The present disclosure is directed, in general to a receptacle and morespecifically, to a backflow collection receptacle and method for usingthe same.

BACKGROUND

Production of oil and gas (e.g., hydrocarbons) from subterraneanformations is dependent on many factors. These hydrocarbons must usuallymigrate through a low permeable formation matrix to drain into thewellbore. In many formations, the permeability is so low that it hindersthe well's production rate and overall potential. In other wells, thenear wellbore is damaged during drilling operations and such damageoften results in less than desirable well productivity. Hydraulicfracturing is a process designed to enhance the productivity of oil andgas wells or to improve the infectivity of injection wells.

In the fracturing process, a viscous fluid is injected into the wellboreat such a rate and pressure as to induce a crack or fracture in theformation. Once the fracture is initiated, a propping agent, such assand (e.g., often referred to as “frac” sand), is added to the fluidjust prior to entering the wellbore. This sand laden slurry iscontinuously injected causing the fracture to propagate or extend. Afterthe desired amount of proppant has been placed in the reservoir, pumpingis terminated, and the well is shut-in for some period of time.

After the pressure is released from the wellbore, the sand, or at leasta significant portion of the sand, remains within the fractured stratathereby holding the strata in a substantially fractured state.Accordingly, the oil and gas is allowed to flow freely. Unfortunately,as the oil and gas begin to flow it starts to push the fluid used tofracture the strata, as well as some unwanted particulates from thestrata (including, frac sand, salts, etc.) back to the surface.

Simple frac tanks are commonly used to collect the unwanted fluid andparticulates that backflow from the wellbore. A typical frac tank isconfigured as a large enclosure having a valve at the bottom thereof,often using a “gas buster” to dissipate the velocity of the backflow.When the frac tank is full of collected fluid, sand, salts,hydrocarbons, etc., an environmentally approved service must be employedto remove the contents thereof. A typical removal process initiates byremoving the fluid from the frac tank via the valve at the bottomthereof. In this situation, as the sand is heavier than the otherparticles, the sand would be at the bottom of the tank. The fluid,hydrocarbons, salts, etc., most of which would be suspended in thefluid, would then be drawn through the sand and collected and disposedof. Unfortunately, the sand, in this removal scenario, becomescontaminated as the hydrocarbons and salts are drawn there through.Therefore, the sand must then be removed from the frac tank andprocessed so as to be safe for the environment. This process ofcollecting, removing, and decontaminating the backflow, including boththe fluid and sand, is an extremely expensive process.

Accordingly, what is needed in the art is apparatus, and/or associatedprocess, which reduces the time and expense associated with thecollection and dispersal of the backflowed contaminants.

SUMMARY

To address the above-discussed deficiencies of the prior art, thepresent disclosure provides a collection receptacle and a method forreclaiming backflow from a wellbore. The collection receptacle, in oneembodiment, includes an enclosure configured to collect solid and liquidmatter, and an elevated auger extending into the enclosure andconfigured to remove the solid matter from the enclosure. In thisembodiment, the auger includes a housing having an outside radius r_(h),a flighting having a radius r_(f), and a shaft of the flighting having aradius of r_(s), wherein r_(s) ranges from about 50 percent to about 65percent of r_(f), and further wherein a relationship between theflighting radius r_(f) and shaft radius r_(s) promotes separation of thesolid matter from the liquid matter as the solid matter travels up theauger and out of the enclosure.

The collection receptacle, in yet another embodiment, includes anenclosure configured to collect solid and liquid matter, and an elevatedauger extending into the enclosure and configured to remove the solidmatter from the enclosure. In this embodiment, the auger includes ahousing having an outside radius r_(h) and a flighting having a lesserradius r_(f), wherein r_(f) is less than about 90 percent of r_(h), andfurther wherein a relationship between the housing outside radius r_(h)and flighting radius r_(f) promotes separation of the solid matter fromthe liquid matter as the solid matter travels up the auger and out ofthe enclosure.

Further provided is a method for reclaiming backflow from a wellbore.The method, in one embodiment, includes collecting solid and liquidmatter from a wellbore within a collection receptacle, the collectionreceptacle being similar to the collection receptacle of the paragraphabove. The method further includes operating the elevated auger in amanner configured to remove at least a portion of the solid matter fromthe enclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present disclosure, referenceis now made to the following descriptions taken in conjunction with theaccompanying drawings, in which:

FIG. 1 illustrates a collection receptacle in accordance with thedisclosure;

FIGS. 2A thru 2E illustrate various views of an elevated auger includinga housing and a flighting;

FIG. 3 illustrates an alternative embodiment of an elevated auger;

FIG. 4 illustrates yet another alternative embodiment of an elevatedauger.

DETAILED DESCRIPTION

Referring initially to FIG. 1, illustrated is a collection receptacle100 in accordance with the principles of the disclosure. The collectionreceptacle 100, as those skilled in the art appreciate, may be used tocollect any number of different types of matter, including solid matter,liquid matter or a combination thereof. In one particular embodiment,the collection receptacle is configured to reclaim, including collectingand dispensing, backflow from a wellbore. For instance, the collectionreceptacle could be configured to reclaim fluid, hydrocarbons, fracsand, salts, etc., that would backflow from a wellbore after fracturingan oil and gas strata.

The collection receptacle 100 of FIG. 1 includes an enclosure 110. Theenclosure 110, in this embodiment, is configured to collect solid andliquid matter. Moreover, the enclosure 110 of FIG. 1 includes a firstportion 120 and a second portion 130. The first portion 120, in thisembodiment, is configured to initially collect the solid and liquidmatter. However, in this embodiment, the first portion 120 has anopening 125 (e.g., weir) in an upper region thereof. The opening 125, inone embodiment, is configured to allow excess collected liquid matter tooverflow into the second portion 130 as the collected solid matter fallsto a bottom of the first portion 120.

In one embodiment, the first portion additionally includes an emergencyopening 127 configured to quickly divert extreme amounts of collectedsolid and liquid matter to the second portion 130. The purpose of theemergency opening 127, in this embodiment, is to prevent overflow of thecollected liquid and/or solid matter from the enclosure 110 in the eventthe opening 125 cannot handle the volume of the incoming solid andliquid matter. As the emergency opening 127 is traditionally only usedin extreme circumstances, the positioning of the emergency opening 127is above the positioning of the opening 125. Accordingly, the emergencyopening, in this embodiment, will only be employed in extremecircumstances. In the embodiment of FIG. 1, the opening 125 is locatedat the rear of the first portion 120, and the emergency opening 127 islocated along the sides of the first portion 120. Nevertheless, thesize, shape and location of each of the opening 125 and emergencyopening 127 may be tailored on a use-by-use basis.

Located within the enclosure 110, and in this example the first portion120, are one or more baffles 140. The baffles 140, in one example, areused to help direct the solid matter to the bottom of the first portion120, among other uses.

The collection receptacle 100 further includes an elevated auger 150extending into the enclosure 110, and more particularly the firstportion 120 of the embodiment of FIG. 1. The auger 150, as would beexpected, is configured to remove one or more contents from theenclosure 110. Nevertheless, in contrast to well known augers, the auger150 is configured in such a way as to promote the separation of thesolid matter from the liquid matter located within the enclosure 110,for example as the solid matter travels up the auger 150 and out of theenclosure 110. Specifically, the auger 150 of FIG. 1 includes a housingand a flighting, and in this embodiment the housing and flighting areconfigured in a manner to promote the aforementioned separation.

Turning briefly to FIGS. 2A thru 2D, illustrated are various views of anelevated auger 200 including a housing 210 and a flighting 220. FIG. 2Aillustrates a cutaway view of the auger 200, whereas FIG. 2B illustratesthe flighting 220, FIG. 2C illustrates a cross-section of the housing210 taken through line C-C, and FIG. 2D illustrates a cross-section ofthe housing 210 taken through line D-D. In referring to the embodimentof FIGS. 2A thru 2D, the housing 210 has a radius r_(h) and theflighting 220 has a lesser radius r_(f), the difference in radiusconfigured to promote separation of the solid matter from the liquidmatter. Because of this lesser radius r_(f) of the flighting 220, theauger 200 creates a solid matter tube surrounding the flighting 220 asthe solid matter is removed from the enclosure. The term solid mattertube, as used herein, is intended to reference a tube like feature usingthe solid matter itself as the tube, as opposed to other rigid materialssuch as steel, iron, etc. The solid matter tube, a sand or mud tube inone example, provides a porous means for the liquid matter to travelback down the auger 200 as the solid matter travels up the auger 200.Likewise, as the solid matter travels up the auger 200 it is squeezed bythe pressure of the solid matter tube against the flighting 220, thusfurther promoting the separation of the liquid matter.

The degree of difference between the housing radius r_(h) and theflighting radius r_(f) can be important to the ability of the auger 200to promote separation. For instance, in one embodiment r_(f) is lessthan about 90 percent of r_(h). In yet another embodiment, r_(f) is lessthan about 75 percent of r_(h), and in yet another embodiment, r_(f) isless than about 67 percent of r_(h). For example, in the embodiment ofFIGS. 2A thru 2D, r_(f) ranges from about 5 inches to about 7 inches,whereas r_(h) ranges from about 8 to about 9 inches.

It has been acknowledged that certain configurations of the auger 150experience issues with the solid matter tube caving in, or sliding backdown to the bottom of the first portion 120. This is particularlyevident when the spacing between the flighting and the housing arelarge. This is also particularly evident in the embodiment wherein thecenterline of the housing and centerline of the flighting do notcoincide. Based upon this acknowledgment, and substantialexperimentation, it has been recognized that blocks 155 (FIG. 1) may beplaced between the flighting and housing at various positioned along thelength thereof. The blocks 155, in this embodiment, typically extendfrom the inside wall of the housing toward the flighting, and in doingso help reduce the likelihood of the solid matter tube caving in. Theblocks 155, in one embodiment, typically extend from the upper mostinner surface of the housing toward the flighting, are located at one tosix different locations, and are not required between the lower mostinner surface of the housing and the flighting. Other configurations,beyond those just disclose, might also be used.

Turning now specifically to FIG. 2B, illustrated is the flighting 220.The flighting 220, as shown, includes a radius r_(f). Likewise, a shaft230 of the flighting 220 includes a radius r_(s). To further promote theseparation of the liquid matter from the solid matter, for example byway of increased pressing on the solid matter, the “teeth” 240 of theflighting 220 extend only a little way from the shaft. For example, inone embodiment, r_(s) should be at least about 50 percent of r_(f). Inan alternative embodiment, r_(s) should be at least about 65 percent ofr_(f), if not at least about 80 percent of r_(f). For example, in theembodiment of FIG. 2B, r_(s) ranges from about 3 inches to about 4inches, whereas r_(f) ranges from about 5 inches to about 7 inches. Tofurther promote separation, the teeth 240 may include notches therein,for example notches extending into the teeth 240 about 0.25 inches toabout 1 inch.

Turning now specifically to FIGS. 2C and 2D, illustrated are thecross-sections of the housing 210. As is illustrated in FIG. 2C, thisportion of the housing 210 has a u-shaped trough cross-section. Incontrast, as is illustrated in FIG. 2D, this portion of the housing 210has a flare-shaped trough cross-section. Nevertheless, othercross-sections could be used.

Turning briefly to FIG. 2E, illustrated is an alternativecross-sectional shape for the housing 210. In this embodiment, as shown,the housing 210 may have a circular cross-section. In this embodiment,the circular cross-section might have a radius ranging from about 8 toabout 10 inches, and more particularly about 9 inches. As the radius ofthe flighting (r_(f)) is less than the radius of the circularcross-section of the housing 210, in this embodiment r_(f) ranging fromabout 5 to about 7 inches, a solid matter tube will likely form. Itshould be noted that in certain embodiments a centerline of theflighting will coincide with a centerline of the circular housing 210.In other embodiments, however, the centerlines will not coincide. Forexample, in one known embodiment the centerline of the flighting will becloser to a bottom surface of the housing 210 than an upper surface ofthe housing 210. In this embodiment, the distance between the flightingand the bottom surface of the housing 210 will be less than a distancebetween the flighting and the top surface of the housing 210.

Turning now to FIG. 3, illustrated is an alternative embodiment of anelevated auger 300. The auger 300 of FIG. 3, in contrast to the degreeof difference between the housing radius r_(h) and the flighting radiusr_(f), includes a drain shoot 315 extending along a bottom surface of ahousing 310 thereof. The drain shoot, regardless of the shape thereof,provides a pathway for excess fluid to travel back down the auger 300 asthe solid matter travels up the auger 300. Accordingly, in thisembodiment the housing 310 and the flighting 320 may have a somewhatsimilar overall shape and radius, but the added drain shoot 315 promotesthe separation of the solid matter from the liquid matter. Accordingly,excess liquid matter squeezed from the solid matter travels down thedrain shoot 315 as the solid matter travels up the auger 300.

Turning now to FIG. 4, illustrated is an alternative embodiment of anelevated auger 400. The auger 400 of FIG. 4, in contrast to the degreeof difference between the housing radius r_(h) and the flighting radiusr_(f), includes a housing 410 having a first portion 413 and a secondportion 418 and surrounding a flighting 420. In this embodiment, thefirst portion 413 is located between the second portion 418 and theflighting 420, and furthermore is perforated to promote the separationof the solid matter from the liquid matter. Accordingly, excess liquidmatter squeezed from the solid matter exits the first portion 413through the perforations therein, and then travels back down the auger400 between the space separating the first and second portions 413, 418,respectfully.

Returning back to FIG. 1, the auger 150 includes a gate 160 at a bottomportion thereof. The gate 160, in this embodiment, is configured toallow solid matter to exit the auger 150 when operated in reverse. Forexample, certain situations may exist wherein solid matter remainswithin the enclosure 110, but there is a desire to fully empty the auger150 of any solid matter. In this situation, the auger 150 could beoperated in reverse, thereby emptying the auger 150 of any solid matter.The gate 160, in this example, allows the auger 150 to rid itself ofsolid matter without putting undue stress or torque on the auger 150and/or its motor. Accordingly, the gate 160 may be opened when the auger150 is run in reverse, and any solid matter within the auger 150 will beefficiently removed therefrom. In the embodiment shown, the solid matterexits into the second portion 130 of the enclosure 110.

The collection receptacle 100 of FIG. 1 further includes a gas buster170 located between the enclosure 110 and a wellbore. The gas buster170, as expected, is configured to dissipate energy associated withincoming solid and liquid matter. In the embodiment of FIG. 1, the gasbuster 170 is coupled to an upper portion of the enclosure 110, forexample near a rear thereof. The collection receptacle 100 of FIG. 1further includes one or more wheels 180 coupled to the enclosure 110.The wheels 180 are configured to allow the collection receptacle 100 toroll from one location to another. Likewise, the auger 150 may includeone or more inspection ports 190, for example with hinged covers,

A collection receptacle, such as the collection receptacle 100 of FIG.1, may be used for reclaiming backflow from a wellbore. In oneembodiment, solid and liquid matter originally enters the first portion120 of the enclosure 110 through the gas buster 170. As the solid mattersinks to the bottom of the first portion 120, the liquid matter (e.g.,the water, salts, and hydrocarbons) float to the top. As the solid andliquid matter continue to fill the first portion 120 of the enclosure110, the liquid matter begins to flow through the opening 125 designedtherein, to the second portion 130 of the enclosure 110. Once the solidmatter approaches the top of the first portion 120 where the opening 125exists, the first portion 120 will be substantially full of solidmatter, while the second portion 130 of the enclosure 110 will primarilycontain the liquid matter.

In certain embodiments, it is important that the revolutions per minute(rpm) of the flighting within the housing is slow enough to remove thesolid matter from the enclosure, while allowing the liquid matter to beadequately removed there from. Accordingly, in direct contrast totraditional auger systems, the rpm of the flighting is intentionallykept slow. For example, in one embodiment the flighting has an rpm ofabout 15 or less. In other embodiments, an rpm of 12 or less providesadvantageous results. In yet another embodiment, an rpm of 8 or less,and more particularly between about 4 and 8, provides superior results.

In this scenario, the liquid matter can be easily removed from the firstportion 120 of the enclosure 110 without further contaminating the solidmatter. The solid matter that exits the top of the auger 150 tends to beonly slightly damp. Moreover, it is believed that this solid matter neednot be decontaminated or reconditioned before being reused or introducedinto the environment. Accordingly, the expense associated with thisdecontamination or reconditioning may be spared.

Although the present disclosure has been described in detail, thoseskilled in the art should understand that they can make various changes,substitutions and alterations herein without departing from the spiritand scope of the disclosure in its broadest form.

1. A collection receptacle, comprising: an enclosure configured tocollect solid and liquid matter; and an elevated auger extending intothe enclosure and configured to remove the solid matter from theenclosure, wherein the auger includes a housing having an outside radiusr_(h), a flighting having a radius r_(f), and a shaft of the flightinghaving a radius of r_(s), wherein a ratio (r_(s)/r_(f)) ranges fromabout 0.5 to about 0.6, and further wherein a relationship between theflighting radius r_(f) and shaft radius r_(s) promotes separation of thesolid matter from the liquid matter as the solid matter travels up theauger and out of the enclosure.
 2. The collection receptacle as recitedin claim 1 wherein r_(f) is less than about 90 percent of r_(h).
 3. Thecollection receptacle as recited in claim 1 wherein the relationshipbetween the housing outside radius r_(h), flighting radius r_(f) andshaft radius r_(s) is configured to create a solid matter tubesurrounding the flighting as the solid matter is removed from theenclosure, the solid matter tube allowing the liquid matter separatedfrom the solid matter to travel back down the elevated auger.
 4. Thecollection receptacle as recited in claim 1 wherein the housing includesa drain shoot extending along a bottom surface thereof, the drain shootconfigured to allow the liquid matter separated from the solid matter totravel back down the elevated auger.
 5. The collection receptacle asrecited in claim 1 wherein the housing is a circular tube having acircular cross-section.
 6. The collection receptacle as recited in claim1 wherein the enclosure includes a first portion that the elevated augerextends into and a second portion.
 7. The collection receptacle asrecited in claim 6 wherein an opening exists in an upper region of thefirst portion, the opening configured to allow excess collected liquidmatter to overflow into the second portion as the collected solid matterfalls to a bottom of the first portion.
 8. The collection receptacle asrecited in claim 7, wherein an output of the elevated auger is locatedabove the opening.
 9. The collection receptacle as recited in claim 1,further including a gas buster located between the enclosure and awellbore, the gas buster configured to dissipate energy associated withincoming solid and liquid matter.
 10. A collection receptacle,comprising: an enclosure configured to collect solid and liquid matter;and an elevated auger extending into the enclosure and configured toremove the solid matter from the enclosure, wherein the auger includes ahousing having an outside radius r_(h) and a flighting having a lesserradius r_(f), wherein r_(f) is less than about 90 percent of r_(h), andfurther wherein a relationship between the housing outside radius r_(h)and flighting radius r_(f) promotes separation of the solid matter fromthe liquid matter as the solid matter travels up the auger and out ofthe enclosure.
 11. The collection receptacle as recited in claim 10wherein the relationship between the housing outside radius r_(h) andflighting radius r_(f) is configured to create a solid matter tubesurrounding the flighting as the solid matter is removed from theenclosure, the solid matter tube allowing the liquid matter separatedfrom the solid matter to travel back down the elevated auger.
 12. Thecollection receptacle as recited in claim 10 wherein a shaft of theflighting has an outside radius of r_(s), and further wherein a ratio(r_(s)/r_(f)) is at least about 0.5.
 13. The collection receptacle asrecited in claim 10 wherein the enclosure includes a first portion thatthe elevated auger extends into and a second portion, and furtherwherein an opening exists in an upper region of the first portion, theopening configured to allow excess collected liquid matter to overflowinto the second portion as the collected solid matter falls to a bottomof the first portion.
 14. The collection receptacle as recited in claim13, wherein an output of the elevated auger is located above theopening.
 15. The collection receptacle as recited in claim 10, furtherincluding a gas buster located between the enclosure and a wellbore, thegas buster configured to dissipate energy associated with incoming solidand liquid matter.
 16. The collection receptacle as recited in claim 10wherein the housing is circular shaped having a circular cross-section.17. The collection receptacle as recited in claim 10, wherein the augeris elevated at about a midpoint between vertical and horizontal.
 18. Amethod for reclaiming backflow from a wellbore, comprising: collectingsolid and liquid matter from a wellbore within a collection receptacle,the collection receptacle including; an enclosure; and an elevated augerextending into the enclosure and configured to remove the solid matterfrom the enclosure, wherein the auger includes a housing having anoutside radius r_(h), a flighting having a radius r_(f), and a shaft ofthe flighting having a radius of r₅, wherein a ratio (r_(s)/r_(f))ranges from about 0.5 to about 0.6, and further wherein a relationshipbetween the flighting radius r_(f) and shaft radius r_(s) promotesseparation of the solid matter from the liquid matter as the solidmatter travels up the auger and out of the enclosure; and operating theelevated auger in a manner configured to remove at least a portion ofthe solid matter from the enclosure.
 19. The method as recited in claim18 wherein the relationship between the housing outside radius r_(h) andthe flighting radius r_(f) is configured to create a solid matter tubesurrounding the flighting as the solid matter is removed from theenclosure, the solid matter tube allowing the liquid matter separatedfrom the solid matter to travel back down the elevated auger during theoperating.
 20. The method as recited in claim 18 wherein the enclosureincludes a first portion that the elevated auger extends into and asecond portion, and further wherein an opening exists in an upper regionof the first portion, the opening configured to allow excess collectedliquid matter to overflow into the second portion as the collected solidmatter falls to a bottom of the first portion.